Physicochemical characterization and solidification kinetics of modified Al–Cu–(Ce)-based gas-atomized powders for PBF-LB

Gas atomization is widely used to produce metal powders for Laser Powder Bed Fusion (PBF-LB). The alloy composition and powder characteristics strongly influence processability; hence, analyzing the raw material is essential. This study investigates the physicochemical, microstructural, and solidification features of two Al–Cu–(Ce) gas-atomized powders, AA2017-0Ce and AA2017-3Ce. Optical and scanning electron microscopy, synchrotron X-ray diffraction, and differential scanning calorimetry were applied to assess solidification kinetics. Density, flowability, contact angle, Hausner ratio, and loss on drying (LOD) were also measured to evaluate PBF-LB processability. Both powders (20–63 µm) showed high sphericity with some agglomerates and satellites. Cerium addition refined the microstructure, forming dendrites surrounded by Al + Al3CeCu + Al8CeCu4. LOD, contact angle, and Hausner ratio indicated that AA2017-3Ce exhibits lower moisture uptake and higher flowability than AA2017-0Ce, demonstrating improved processability for PBF-LB. Graphical abstract